Composition roofing



Marx 2h 22, LEV|N v OOMPOSITION ROOFING Original Filed Feb. 27, 1929 2 Sheets-Sheet l INVENTOR Hamil .5 L'e rzrb ATTORNEY March 22, 1932. H. L, LEVIN COMPOSITION ROOFING Origifial Filed Feb. 27, 1929 2 Sheets-Sheet INVENTOR Jyzmla Z. Zerr'rv ATTORNEY Patented 1932 i 'u mrso STA-res PATENT orrlcs more) L. or nurnnnronn, nnw mess assrenoa, BY HESNE'ASSIGNMENTS,

are THE rn'rnur AND Lrcmrsme coaromrron, or nosrou, mssacnusnms, a

CORPORATION OF MASSACHUSETTS comeosrrron' aoorrne Application med February 27, 1929, Serial No. 848,1b3.- Renewed September 10, 19 811 5 My invention concerns itself particularly with the production of a composite roofing material from a base of felted fibrous material suitably waterproofed and weatherproofed. A common form of composition roofing made from a base such as that de scribed, is one wherein the felted foundation is waterproofed by impregnation with a relatively inexpensivewaterproofing agent such as asphalt, the waterproofed foundation be- 16. ing thereafter supplied with a coating layer of asphalt enerally of a high meltin point variety Wiiiill which is partially em edded a surfacing layer of crushed mineralmatter such as crushed slate, or the like, adapted in '20 one respect to protect the coating layer againsttheldeteriorating influences of the o solarrays, etc. Composition roofing as thus prepared is in extensive useat the present time, but it suflers the objection that because 3 of'the relatively thin and flat nature of the material, it lends a rather monotonous appearance to a roof when applied thereon in successive courses of shingles. Someslight alleviation of this objection is had by using .30 as the base, a felted foundation of higher caliper, but this can only berealized within certain limits in commercial practise, and even with the heaviest grades of felt commercially available, the objection of thinness is not entirely eliminated, and moreover, the costinvolved in using heavier grades of felt increases inordinately the cost of roduction ofthe roofing since the felt base is themost 40 of material. p i

.PIt has been proposed to make composite roofing material by methods directed towards increasing the thickness of those ortlons of the roofing which will be expose when the ing and surfacingmaterial over at least the exposed areas of'the roofing, but since the m limitsof thickness of each layer of coating product, and furthermore, the material emhancing the durability, permanency, as well costly element inthe manufacture of this type roofing is applied. These methods general-- '1 ly involve the use of addltional layers of coatand' surfacing are ,comparatively small, the

ultimate thickness of the roofing is increased only to a slight degree by these methods, unless such a large number of successive depositions of coating and surfacing are employed as to make the process of manufacture commercially unfeasible. .Moreover, since these methods require the use of a plurality of layers of surfacing material in building u the required thickness, the final product is of inordinate weight per unit area, due to the high specific gravity which characterizes the surfacing materials generally available and .utable for this purpose.v

By my invention, I am enabled to produce a very thick constructionof the composite '55 roofing, even where arelatively thin base'or felted foundation is used, in a very simple manner, and without materially increasing the unit weight of the product, that is to say, the thickened eflect is secured in such a way that the unit weight of the product is-much less than inproducts of corresponding, thick.- ness heretofore known to me. Moreover, in accordance with my invention, the desired thickness is achieved by means which not only increases the material bulk at exposed areas, but also serves to reinforce the roofing so as to impart increased strength thereto while preserving the flexible nature of the finished ployed for accomplishing the foregoing results is of a waterproof character, making it very durable in itself, and on the wholeenposed areas of the product shown in Fig.- 'ure 1;

Figure 3 is an enlarged cross section taken transversely through the product;

7 Figures 4' and 5' are details of material w which ma be employed in building up the product 0 my invention;

Figure 6 is a plan view of a roofing unit which may be employed as the base for my improved product, and

Figures 7 and 8 are similar views indicat ing subsequent and successive stages of treatment of the base unit shown in Figure 6.

In accordance with my invention, I may start with a base of felted fibrous materials in the form of continuous sheets, impregnated in the customary manner with waterproofing material, and provided on a surface thereof, with a coating layer of waterproof ma terial, such as blown asphalt having a melting point somewhat in excess of 200 F. In place-of a felted foundation, any other suitable roofing base may be employed.

While the coating layer is\still in more or less heated state, or at least in plastic and adhesive condition, I shower or otherwise apply thereover, or at least over the areas thereof which are to form the exposed areas of the finished roofing, a layer of bitumen-containing fibrous material in the form of compact and firm elongated pellets or fragments of appreciable thickness.

These pellets consist of a homogeneous mass composed essentially of fibers either of animal, vegetable, or mineral origin, and bitumen such as asphalt, the fiber and bitumen being first brought into a homogeneous plastic condition by any. suitable form of aparatus, and the pellets being then formed rom the homogeneous mass b extruding the mass through suitable extru ing devices.

Various grades of bitumen and fibrous materials may be, used, and in proportions varying within reasonably wide limits. The consistency of the mass and the hardness of the pellets made therefrom, will, of course, be governed by the relative proportions of the bituminous and fibrous materials, as well as by the character of the constituent materials, and by usin bitumen of various grades of hardness an various grades of fibrous maof 110 to 200 F. and a penetration of 30 to I conveniently thoroughly incorporating the fiber with the bitumen and forming a plastic homogeneous mass thereof, and to this end the mixer is preferably provided with steam jackets or the like, to permit a regulation of the temperature therein suificient to keep the bitumen in more or less fluent condition.

The plastic mass of bitumen and fiber when sufliciently homogeneous, is then transferred to the extruding mechanism, or the latter may be formed as part of the mixing device. The extruding mechanism may be of any convenient form, provided with dies through which the plastic mass is forced under pressure, the extruded material taking the form of substantially continuous threads or filaments, as shown as 10 in Figure 4, of any desired thickness and of circular, rectangular or even annular, or other desired cross-sectional configuration. The extruding device is preferably further provided with means such as a revolving cutter, for chopping the extruded threads as they emerge from the extruding dies, into pellets as shown at 11 in Figure 5, varying in size from to 1" in length.

The pellets as thus constituted and formed, and being relatively warm, may show some tendency to adhere one to another when they are collected and stored before use, and in order to avoid this tendency, I may spray the pellets as they are formed, or immediately thereafter, with a suspension of nonadhesive material such as clay or the like; or in some cases, they may be delivered to a tank of dilute water suspension of clay, the temperature of which is maintained low enough to preclude substantial adhesion of the pellets. Another means by which to prevent the pellets from adhering one to another after their formation, is to subject them immediately after formation, to an atmosphere of cold air'whereby they will be chilled to a temperature sufiiciently low to prevent them from sticking together.

As the pellets are showered onto the saturated felted foundation covered with the coating layer of sticky asphalt, as already described, they will arrange themselves in various directions and will be more or less interlaced one with another, in which condition they will become attached to the foundation by the adhesive condition of the coating layer and the sheet thus treated may then be passed beneath another spray of asphalt, over which surfacing material of slate or the like, of any desired color, may be applied in the customary manner. As will be understood, the pellets are firmly attached to the sheet by the first coating layer and are further sealed in by the second application of asphalt which also servesasj the medium for securing to the sheet the usual mineral surfacing. In order to cause the mineral surfacing more firmly to imbed itself into the outermost coating layer,

i the sheet may be passed under the usual press rolls.

The additional thickness afforded by the use of the pellets as described, will de end upon the average diameter or thickness the pellets, as will be obvious. I prefer to make the pellets of a thickness of about ",'al-' though this may be varied in'either direction depending upon the ultimate thickness desired. Generally, the pellets themselves will be greater in thickness than the felted base, and in many instances greater than the aggregate thickness of the felted base and the superposed coatings of asphalt and mineral surfacing. It will be appreciated that the indiscriminate and interlaced arrangement of the pellets will provide numerous depresrials like crushed slate. Moreover, due to* the nature of this bulking medium, and its disposition over the sheet, the flexibility of the roofing is substantially preserved despite the great increase in thickness. Again, the pellets, being composed largely of bitumen and thoroughly incorporated therewith, are,

highly waterproof, and thus increase the durability of the product in use. Furthermore, the pellets, being more or less of elongated form, and arrangedon the sheet as described, serve as reinforcements for the sheet whereby they materially increase the strength of the finished roofing.

In Figures 1, 2 and 3, I have shown what is known commercially as a square-buttstrip shingle in which is embodied the features of my invention as the same appears when cut from a finished sheet of goods. Numeral 20 indicates the saturated felt base, the coating material therefor being indicated at 21. The pellets applied to the coating layer are shown at 22; As already explained, additional asphaltic coating material may be applied subsequent to the deposition of the pellets upon the coated sheet, but the second coating application, being quite fluid when applied, will find its way through the crev- 4 ices or interstices between adjoining pellets and flux or amalgamate with the coating material-first applied, and for that reason it isv somewhat difiicult to illustrate the separate coating applications on the drawings, but this feature as well as the purpose and advantages thereof, will be clearly appreciated by those skilled in the art. The mineral surfacing applied to the sheetafter the application of the second coating is indicated at 23. The

lets.

rugged appearance of the exposed areas of the product, which is highly desirable from an artistic pointof view, is plainly visible in the finished product, and is indicated as well as can be, in Figure 1. This feature of a rugged appearance is a most desirable and advantageous feature of my invention, butwhere it is desired to reduce this appearance in greater or less measure, this may be readily accomplished by using pellets of varying sizes and configuration, so that those of smaller size will occupy the spaces between those of larger size. The vari-sized and configured pellets may be either simultaneously extruded, or one may separately form pellets of the varioussizes and configurations, and thereafter commingle desired proportions of the different sizes, etc.

'I have heretofore referred to these pellets as being constituted essentially of fiber and bitumen, but it shouldbe understood that I may introduce in the mixture from which the pellets are formed, mineral fillers such as talc, slate, slate dust, hydraulic cement, etc., for imparting increased hardness'to the pel- A desirable and economically advantageous feature of my invention is the ease and cheapness with which the pellets may be made from scrap roofing material of the felt-base asphalt saturated and coated type. In the commercial manufacture of certain so-called roofing strips, particularly those wherein individual shingle effects are simulatedin strip form by cutting notches or recesses in the strips, the material cut away to form the notches or recessesand constituting about 3% of the material used to make this form.

of strip, represents just that much waste, and in addition, imposes upon the manufacturer a troublesome problem of disposal. In

forming the pellets ofmy invention, I may utilize this waste material, inasmuch as the fibrous and bituminous content thereof is substantially that required to produce a desired consistency of the plastic mass from which the pellets may be formed. In this way, the pellets can be produced at an exceedingly low cost, while at the same time the normal waste aroundthe roofing plant can be reclaimed and profitably utilized. I s 4 This waste material iscomposed generally of about 15 to 20% fibrous matter, 55 to 60% asphalt and 25 to 35% mineral matterin the form of crushed slate associated with the waste material as surfacin Aisthus composed, this waste is admirah scribed.

In someinstances when usin roofing waste production of the pellets. The removal of v l suited for the production of the pellets in the manner de-' the mineral grit may be effected in numerous ways, but I prefer to soak the waste in hot water so as to cause the mineral grit or granules, to be released from the fibrous asphalt saturated and coated base, the granules being then separated and the remaining constituents, after partial or complete removal of the entrained water, transferred to the mixing or grinding device for making the plastic mass to be extruded in the form of pellets.

Where the bitumen and/or fibrous content of the reclaimed waste material does not substantially meet the requirements for a plastic mass of the desired consistency, there may be added to the batch in the mixer further quantities of bitumen and/or fibrous material, as well as finely powdered mineral matter, and to this end I may use all manner of waste occurring around the roofing plant, such as scrap felt, scrap asphalt saturated felt, or scrap asphalt saturated and coated felt. The amounts necessary to produce a mass of desired plasticity and pellets of the required hardness from these various materials will be readily ascertainable by the skilled operator.

In some instances I may coat the pellets with mineral surfacing without employing therefor an intervening layer of asphalt as hereinabove described. To this end, the pellets may be passed through a current of warm air or gas as they are being supplied to the roofing, or the pellets may be fed directly from the forming mechanism to the sheet. In either event, the pellets would be sulficiently sticky to permit the retention of mineral surfacing deposited over the surface of the sheet covered with the pellets.

I may also, in accordance with my invention, form colored pellets by the use of a light colored bitumen of suitable hardness and form a plastic mass thereof with fibrous material, the mass being brought to desired color by incorporating suitable quantities of mineral pigment therein. Colored pellets thus formed may then be used as the finish surfacing for the roofing, thus making it unnecessary to use additional coating and mineral grit surfacing.

Instead of applying the pellets to the sheet prior to separation of shingle or shinglestrip elements therefrom, I may in some instances pre-form the shingles of the saturated felt base,-in any desired size and configuration, and thereafter apply to the pro-formed shingle elements, a layer of adhesive waterproof material, as for instance, by submerging the elements individually in molten asphalt, whereupon the pellets may be showered onto the coated element, and the latter then treated as desired for application of a mineral surfacing layer thereto. By this procedure, the pellets will become atfixed not only to the weather-exposed surfaces of the elements, but likewise to the butt and side edges, as well as to the underside thereof, thus further enhancing the thickness, strength, and durabilsquare butt stri shingle as above described.

The saturated elt base strip pre-cut to the square butt configuration is shown at 30 in Figure 6, immediately after it has been submerged and withdrawn from a coating bath so as to supply the surfaces thereof with a coating layer of asphalt, the latter being in-' dicated at 31. Preferably the coating 31 extends to a-line slightly above the upper ends of the cut-outs or tab-defining recesses 32, as indicated by the dotted line in Figure 6. After the desired thickness of coating has been accumulated upon the surfaces of the shingle, the pellets 33 are applied to the coated areas, as for example, by contacting the coated and sticky shingle with a bed of the pellets, the latter adhering and becoming af fixed to the shingle by the adhesive nature of the coating. This stage is indicated in Figure 7. Coating material, as indicated at 34 in Figure 8, may then be applied over entire surface of the shingle, including the uppermost portions thereof as well as the portions carrying the pellets, whereafter mineral surfacing of any desired character may be partially imbedded in the coating 34, as will be well understood. As will be noted from Figures 7 and 8, the butt and side edges of the element also present an uneven and rugged appearance due to the fact that numerous pellets adjacent said edges extend more or less thereover, in various directions, thus further enhancing the texture of the product and increasing the shadows cast by the butt edges when the elements are laid in courses on a roof.

Having thus described my invention in several embodiments thereof, it will be understood that numerous-variations may be made therein without departing from the spirit of the invention as set forth in the claims hereunto appended.

I claim as my invention:

1. Composition roofing comprising a felted foundation and an overlying layer of pellets composed essentially of bitumen and fiber.

2. Composition roofing comprising a waterproof base and an overlying layer of waterproof pellets composed essentially of bitumen and fi er.

3. Composition roofing comprising a waterproof base and an overlying layer of waterproof pellets composed essentially of bitumen and fiber, said pellet layer being greater in thickness than said base.

4. Composition roofing comprising a waterproof base and an overlying layer of pellets composed essentially of bitumen and fiber, said pellet layer being united to said base by an intervening layer of adhesive waterproof material.

5. Compositionroofing comprising a'felted fibrous foundation, an overlying layer of pellets composed essentially of bitumen and fiber, and an external surfacing layer of mineral grit.

6. Composition roofing comprising a felted fibrous foundation, an overlying layer of pellets composed essentially of bitumen and fiber, and-an external surfacing layer ofmineral grit, the thickness of said pellet layer being in excess of the aggregate thick- ..ness of said foundation and said surfacing layer.

' 7. Composition roofing comprising a felted Waterproof base, a bulking layer adherent to said base and being composed of waterproof pellets arranged indiscriminately in said layer to provide numerous elevations and intervening depressions, and an external surfacing layer .of mineral grit overlying said pellets and in said intervening depressions.

8. Composition roofing comprising a waterproof base and an overlying layer of waterproof pellets composed essentially of bitumen and fiber, said pellets being of elongated form and arranged in interlaced relation with one another upon said base. v9. Composition roofing comprising a 'gwaterproof felted fibrous foundation, an overlying layer of waterproof coating material, a layer of pellets composed essentially of bitumen and fiber superposed over said coating layer and an external surfacing layer of mineral grit.

10. Composition roofing comprising a ,waterproof felted fibrous foundation, an overlying layer of pellets composed essentially of bitumen and fiber, a layer of waterproof coating material covering said layer of pellets, and an external surfacing layer of mineral grit.

11. Composition roofing comprising a waterproof felted fibrous foundation, an overlying layer of pellets composed essentially of bitumen and fiber, a layer of water- 7 proof coating material covering said layer of pellets, said pellet layer being united to said foundationby an intervening layer of Y adhesive waterproof material, and an external surfacing layer of mineral grit.

Signed at Rutherford, in the county of Bergen and State of New Jersey, this 15th day of February, 1929.

' HAROLD LEVIN. 

